Diversity: packaging at its best

KOCH expertise in packaging

applications for consumer products

Diversity: packaging at its best

02 03Expertise in consumer products

Most diverse products effectively presented and protectedFlexibility as the foremost principle

Diversity: packaging at its best

Cosmetics and beauty products: mascara, lipstick,

lip balm, nail polish, make-up, …

Personal hygiene products: razors, razor blades,

creams, manual or electric toothbrushes, manicure sets, …

Household items: air fresheners, pocketknives,

dowels, toys, garden tools, fertilizer sticks, lighters, …

Office products: adhesive film, printer cartridges,

pencils, ballpoint pens, erasers, USB flash drives, …

Batteries: button cell batteries, all other types, …

Car parts: spark plugs, brake disks, windshield wipers, …

Razor set in a blister-to-blister pack formed to the shape

of the products

Lip balm in KOCH cyclePac®

Pacifier setprotected in a face

seal blister allowing product and brand

recognition

Innovative packaging technology plus comprehensive know-how,

perfected over some 50 years, form the basis upon which we

develop and realize machine solutions that are as individual as

your products and your requirements. Whether transparent rigid

blisters, soft blisters using less material, or sustainable forms of

packaging, every type protects your product, presents it in a clearly

visible and appealing manner, and ensures brand recognition.

Flexibility, the underlying principle of all KOCH packaging tech-

nology, is attained with the modularity of the machines and lines.

Taking a basic module and additional components, we shape a

cost-efficient, reliable packaging process in compliance with your

specifications. For the semi-automated sealing of preformed blisters

or carton blanks, for the fully automated forming, filling, and sealing

process, and for the integrated handling of your products, from

feeding to end-of-line packaging. All key technologies are com-

bined at KOCH. This enables us to monitor and control the quality,

deadlines, and costs of your project at all times.

Type

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KOCH

SP

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04 05Types of packaging

The right solution forevery type of packagingFor a productive packaging process from the start

KDT KS-PT KS-PLS sealing KDTKDT KS-PT KS-PL KDT KS-PT KS-PL KBS-KF

KBS-PT KBS-PL KBS-KF

shawpakFFS forming filling sealing KBS-KF KBS-PT KBS-PL KB-KF plus KS-PL in lineKBS-KF shawpak KBS-KF shawpak

Face seal blister Blister to blister (double blister)

Trapped blister ClamshellBlister with lid material from roll

Soft blister

KDT KS-PT KS-PL

KBS-PT KBS-PL

cyclePac®

In addition to attractive presentation, packaging should protect the product. In the case of

cosmetic articles, for example, it should be completely tight to ensure hygienic conditions until

opened. Another increasingly important criterion is eco-friendliness. The inclusion of information,

as well as the easy opening or reclosing of the packaging, are likewise demands we address.

We design the packaging accordingly, attune it to the technical capabilities of your machine,

and develop a productive packaging process. Productive with regard to primary and secondary

packaging, and also in terms of the form and costs of production: simple and low-priced for

mass products, more sophisticated for products of higher value.

The key component is an individually configured KOCH blister machine. This comprises a basic

module for forming, filling, and sealing (FFS), or just for sealing (S), plus additional components.

The best solution also requires the right choice of suitable materials, their economical use, and,

if required, mono-material recycling of the packaging components.

Rectangular blister smaller

than the backing card

Sealing of the blister to

the ready-made card

Forming of two identical

or differing blister halves for

the front and back

Filling of one blister half

Sealing of the two halves

Cutting and/or punching of

the blister – only possible

with KBS-KF

Rectangular blister smaller

than the cards

Collation of the backing

card, loosely inserted blister,

product, and punched front

card

Sealing of front and back card

with hidden sealing edge

Forming and cutting/

punching of the open

halves

Filling of the preformed

halves

Closing of the clamshell

Semi-automated, just with

sealing of the preformed

blister

Semi-automated, just

with sealing of the front

and back cards

As reclosable wallet

As reclosable wallet As reclosable wallet

Packaging process

Product description

Optional

Flexible packaging requiring

less material, permitting the

ideal pack size for flexible

products

Eco-friendly, e.g., suitable

for sturdy, securely closed

products

Versatile pack, e.g.,

containing more than one

of the same product

Transparent pack, e.g., for

immediate recognition of

product variations

Tight pack, e.g., for

susceptible products

Optically superior pack, e.g.,

for products with anti-theft

protection

Reasonably priced production

form, e.g., for low-priced mass

products

Forming of two identical

blister halves for the front

and back

Filling of one blister half

Sealing of the two halves

Cutting of the blister

Forming of the cardboard

cover out of prepared

blanks cut smaller than the

ready-made backing card

Product placement and

sealing of the cardboard

cover to the backing card

Forming, filling, and sealing

of the blister

Cutting or punching of the

blister

06 07Package the smart way

Package the smart way

KOCH expertise in sustainable packaging

Sustainable and sustainably intelligent

As far as sustainability is concerned, we set our sights on the big

picture: protection of the environment by using materials from

recycling or bio-based sources. We apply packaging and processes

that require less material and attain brand presentation using

packaging forms made of sustainable materials. All are extensively

tested and suitable for straightforward, reliable, and productive

processing on KOCH blister machines.

Save material with innovative processes

We apply innovative methods and technology to further reduce

the use of material during processing. The patented smart heating

function permits perfect regulation of the material thickness.

Smart forming increases the forming pressure for optimized blister

quality and a higher cycle rate. Other examples include tools at

the right temperature for perfect blisters from the first cycle and

special cutting methods that significantly save material, particularly

when packaging small products.

Package the smart way

Whether cyclePac® mono-material packaging made of cellulose,

blisters formed using sustainable films or formable paper, our

experts customize every packing design to perfectly match your

product and process requirements. We intelligently combine various

factors according to the motto “Package the smart way”.

Integral solution combining pack design and packaging

technology

Sustainable materials from recycling or bio-based sources

Full and repeatable recycling of packaging materials

Improved product-pack ratio

Reduced use of material during processing

End-to-end packaging concepts (blister to pallet) for

optimized transport and logistics

cyclePac®: USB stick in cardboard tray – with perforation

and high-quality printing

Eco-friendly blister formed from sustainable film as an alternative

to a conventional rigid blister

cyclePac®: quality, brand-name pen with ink cartridge in an inlay card; placed in a

cardboard tray; sealed with a backing card

Type

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age

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KOCH

SP

KS-P

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KBS-

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Turntable Machine KDT – basic model

The shawpak KOCH SP with an output of 25 blisters per minute

08 09Sealing and Blister Machines

Flexibility in a compact format Turntable Machine KDT and Forming and Sealing Machine shawpak KOCH SP

Turntable Machine KDT

The cost-effective packaging of small to medium-sized

batches is where the KDT comes into its own with its

low purchase price, reasonably priced format parts,

economical energy consumption, and well-devised

machine concept with state-of-the-art technology.

The basic machine version incorporates a turntable

with four sealing tools and a unit for thermal sealing.

Extension options

An additional card placer system allows the automated

feeding of different packaging elements such as blisters,

lid material from the roll, or as blanks or front cards

for trapped blisters. The KDT can be automated using a

product feeder and other components

Forming and Sealing Machine shawpak KOCH SP

The productive heart of the machine is the servo-driven

forming drum. As it transports the webs through the

process without any gripper chains, it is very efficient

and low in maintenance. The product is simply loaded

into the top of the form ing drum, either manually or

using a robot handling system. The single-lane mode

of operation ensures a smooth process and precision

monitoring. Guided operation is straightforward using

the color touchscreen. The shawpak KOCH SP is available

with various format areas and blister depths of 80 or

100 mm.

Type

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Pack

age

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KDT

sha

wpa

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PKS

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KB

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KOCH

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Face seal blister Face seal blisterTrapped blister Blister with lid material from roll

Blister with lid material from roll

Blister types KDT Blister types shawpak KOCH SP

Blister to blister (double blister)

cyclePac® Soft blister

Modular configuration of the Turntable Machine KDT

Lid material feeder with punch/without punch

Film blank and backing card placer

Front card placer

Horizontal blister magazine

Package output

Automatic product feeder

Turntable machine with sealing station

Package output with marking

and inspection

Backing card placer

Technical data KDT

Blister depth: up to 70 mm

Sealing format: 250 x 360 mm

Sealing force: 30 kN

Output: 12 cycles/min.,

depending on

packaging material/

shape, and

sealing duration

Technical data shawpak KOCH SP

Forming area: from 220 x 200 mm

to 620 x 250 mm

Blister depth: max. 100 mm

Output: up to 25 blisters/min.

10 11Sealing and Blister Machines

Fast format changeovers, high packaging capacity, and processing flexibility for diverse formats using

conventional or sustainable materials: the Sealing and Blister Machine KBS-PT effortlessly meets these

requirements. Maximum flexibility is attributed to two aspects: quickly exchanged sealing pallets and,

essential for economical small-batch packaging, the necessity to only replace individual format parts when

a format is changed. Configuration with the Sealing Machine KS-PT is recommended for the processing

of preformed blisters.

A distinctive technical feature of the KS-PT and the KBS-PT is the octagonal pallet transport. Each

machine has a compact footprint, is easily accessible, and allows straightforward loading. The addition

of other stations and components is possible at all times – enabling subsequent extension to form a

KOCH packagingLine.

Multi-talent – material, format, and batch size flexibilitySealing Machine KS-PT and Blister Machine KBS-PT

with octagonal pallet transport

Blister types

Blister Machine KBS-PT with forming material feeder, forming station, sealing station, and octagonal pallet transport

Face seal blister Trapped blister Blister with lid material from roll

cyclePac®

Front card and cardboard mono- material pack placer

Blister transfer


Extension pallet transport (variable)

Pallet transport (octagonal)

Marking (inkjet, laser)

Sealing station

Card placer Package unloader

Package output

Labeler

Forming station

Forming material feeder

Hanger hole punch

Split cut punch

Forming material buffer

FORMING

FILLING

SEALING

KBS-PT

KS-PT

Modular configuration of Blister Machine KBS-PT or Sealing Machine KS-PT

Technical data

Forming area: 250 x 500 mm

Forming depth: 67 mm



depending on

forming material,

packaging shape/size,

and sealing duration

Blister forming station with longitudinal film cutting device

Type

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Pack

age

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KDT

sh

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KBS

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Thermal sealing station of the Blister Machine KBS-PL

12 13

The Sealing Machine KS-PL and the Blister Machine KBS-PL productively package large batches of the

same or similar products. Both reliably process standard or sustainable films, as well as cyclePac® card-

board qualities. Characteristic of both machines are the large format and sealing area – suitable, for

example, for large-format, stand-up blisters or hanging blisters with a standard hanger hole – as well as

the pallet section. This can be served manually or by a robot. The user-friendly, clear-cut design allows

full control of the packaging process at all times.

With a high number of cycles for large batches Sealing Machine KS-PL and Blister Machine KBS-PL

with linear pallet transport

Blister Machine KBS-PL– highly efficient packaging using proven technology – for blisters made of PVC, PET, or sustainable films, such as RPET, bio-based PET, or PLA

Sealing and Blister Machines

Type

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Pack

age

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smar

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KDT

sh

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KOCH

pac

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Face seal blister Trapped blister Blister with lid material from roll (only with KS-PL)

Blister types

cyclePac®

Technical data

Forming area: 250 x 500 mm




depending on

forming material,

packaging shape/size,

and sealing duration

Extension pallet transport (variable)

Sealing station

Card placer

Card placer

Forming station



Labeler

Hanger hole punch

Split cut punch Hanger hole punch

Marking (inkjet, laser) Package output


FORMING

FILLING

SEALING

Pallet transport

(linear)

KBS-PL

KS-PL

Modular configuration of Blister Machine KBS-PL or Sealing Machine KS-PL

14 15

Exemplary version of Blister Machine KBS-KF with lid material from roll

Whether rigid or soft blisters, whether standard or sustainable materials, and whether sealed or with lid

material, the Blister Machine KBS-KF packages a wide range of products at high speed. The large forming

and sealing format as well as a maximum forming depth of 70 mm permit the processing of individual,

bulky products or multipart sets.

The optimum sealing technology is selected to suit the lid material – foils, aluminum, or Tyvek®. The

robust, smooth-running chain conveyor allows reliable, accurate product transfer from station to station,

as well as maximum machine uptime.

Ample format range, forming material diversity, and functional reliabilityBlister Machine KBS-KF with chain conveyor

Sealing and Blister Machines

Type

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pac

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Pack

age

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KDT

sh

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Face seal blister Blister with lid material from roll

Blister to blister (double blister)

Soft blister

Blister types

Modular configuration of Blister Machine KBS-KF


Heating station

Labeler

Lid material feeder

Marking (inkjet, laser)

Package output


Leaflet placer

Full or split cut punch


Sealing station

FORMING

FILLING

SEALING

Forming station

Forming material transport via chain conveyor

Punching station

Technical data

Forming area: from 150 x 300 mm

t0 500 x 500 mm


Sealing format: from 150 x 300 mm

to 500 x 500 mm


depending on packaging

material/shape, and

sealing duration

Chain transport with forming station

1

2

3

45

6

1 2 3 4 5 6

Forming End-of-line packaging

Product handling (filling)

Sealing Grouping Cartoning

Fully integrated and highly flexible packaging As individual as your requirements

16 17KOCH packagingLine

Your specifications and our machines form the basis on

which we develop a highly automated, flexible, and

productive line. Fast, straightforward format changeovers

ensure maximum machine uptime, while the concept

allows the processing of small- as well as large-format

products. It is also possible to incorporate various

packaging formats in a universal pack – for optimized

storage and logistics, as well as easier retail handling.

The basic version of every KOCH packagingLine incorpo-

rates four perfectly synchronized components: a blister

machine, a product feeder, a blister grouping module,

and end-of-line packaging. Fully automated feeding and

product placement are possible using a robot handling

system – accurate and reliable with a high pick rate. As

required, we also integrate systems for inline marking

and inspection, and for high-quality, customized printing.

Straight forward, reliable operation is ensured by in cor-

porating all components, including those from other

manufacturers, in a seamless, end-to-end IPC control

system.

Guaranteed process quality – from a single source

At all stages – from the concept and packaging design to

integration into ERP/MES systems and existing SCADA

control systems – our expertise is at your disposal. As

your premium partner, we are responsible for the entire

project, offering a turnkey service from a single source.

Included are documentation, in-house qualification,

and globally available support services for long-term,

smooth operation of your KOCH packagingLine.

Type

s of

pac

kagi

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Pack

age

the

smar

t way

KDT

sh

awpa

k KO

CH S

PKS

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KB

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KOCH

pac

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ort +

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KOCH Training

KOCH Support + ServicesFor highly productive packaging over the entire life cycle

Installation and Commissioning

Machine acceptance at KOCH

Professional dismantling and

transportation

Installation at the customer’s

premises by qualified personnel

Renewed machine acceptance with

detailed protocol

Start-up assistance through

personnel training and production

support

Technical Support Machine Availability Automation and Integration Format and Spare Parts

smartpacks

Basic Training:

After or during acceptance

Machine-specific Basic:

After installation, an upgrade, or an

extension; based on basic training

and machine operating instructions

Machine-specific Advanced:

Content according to needs, with

training at supplementary components

and customized, machine-specific

training documents

Start-up Support:

Provided by a service technician after

commissioning

Telephone and e-mail support

through the service hotline

Germany: +49 7445 181-181

[email protected]

USA: +1 973 936-1001

[email protected]

Singapore: +65 9072 9723

[email protected]

Online support via remote access

Coordination of service visits including

material planning and personnel

scheduling

Repair and maintenance on site or

at KOCH

Temporary production support

Individual service agreements for

inspection and maintenance

Machine upgrades with coordinated

tools

Production analysis and output

optimization

Machine relocations with

recommissioning

Higher level of automation with

components for feeding, monitoring,

and marking

Integration of all process steps – from

grouping to end-of-line packaging

Machine qualification according to

customer requirements

Design and production of custom-fitted

tools from a single source

Top quality and precision for long

service life

Optional qualification documentation

Original spare parts for all current types

of machine

Standard parts immediately available

Line-specific spare parts packages

Faster machine commissioning –

using a virtual model

Access to production data using the

KOCH smart app

End-to-end, user-friendly IPC control

system

Online ordering of specific machine

parts – using the SparePartsManager

– digital services for an easier and more efficient daily packaging routine

Digital services perfectly combined

Instruction Pack

Lifecycle Pack

Connectivity Pack Usability Pack

Predictive Pack

OEE Pack

Eco Pack

Production Pack

AuditTrail Pack

Lifecycle Pack

18 19KOCH Support + Services

Type

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KOCH

pac

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KOCH

Sup

port

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20 21The Uhlmann Group

The Uhlmann Group specializes in the development and provision of solutions that

ensure the reliability and integrity of sensitive products. With a focus on the digitalization

of production and packaging processes, the companies of the Uhlmann Group provide

a variety of market sectors with innovative solutions, services, and technical expertise

extending way beyond pure packaging. The Uhlmann Group is represented worldwide

at 19 locations in 14 countries.

Uhlmann Pac-Systeme GmbH & Co. KG

is a leading international systems

partner for integral, flexible packaging

systems, services, and digital solutions

for pharmaceutical products. Uhlmann

sets standards with high-end products

that meet the most exacting reliability

and quality demands. The portfolio

covers all steps of the packaging

process and includes machines and

lines for packaging in blisters, cartons,

and bottles.

Founded 1948

Employees approx. 1,650

Headquarters Laupheim

(Germany)

Cremer Speciaalmachines B.V.

is a globally operating company

specializing in counting and packaging

solutions, as well as services for the

pharmaceutical, food, consumer goods,

and agricultural sectors. Cremer also

offers pharmaceutical lines for the

packaging of tablets in bottles. The

portfolio ranges from concept develop-

ment to the turnkey supply of counting

systems and packaging lines.

Founded 1949

Employees approx. 150

Headquarters Lisse (Netherlands)

KOCH Pac-Systeme GmbH

offers tailored solutions for complex

packaging operations in the fields of

medical devices, contact lenses, and

consumer goods. Using modular

machine technology as a basis, KOCH

develops a reliable, flexible packaging

process that may range from an intelli-

gent standalone solution to a highly

automated KOCH packagingLine. Exten-

sive support options and K 4.0 digital

services complement the portfolio.

Founded 1969


Headquarters Pfalzgrafenweiler

(Germany)

Jinzhou Wonder Packing Machinery Co., Ltd.

specializes in the development, manu-

facture, and sale of packaging machines

for the pharmaceutical industry, and

provides support services. The focus is

on products and services for emerging

and cost-conscious markets. The

portfolio includes blister machines,

cartoners, and four-side sealed sachet

machines manufactured to German

quality standards.

Founded 1998


Headquarters Jinzhou, Liaoning

(China)

KOCH Pac-Systeme GmbH

Dieselstrasse 13

72285 Pfalzgrafenweiler

Germany

Phone +49 7445 181-0

Fax +49 7445 181-50

[email protected]

www.koch-pac-systeme.com Con

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Documents

Diversity: packaging at its best